Plant structure - Porcess automation system (pdf ... - Schneider Electric

Process Automation System

Your challengesl Reduce engineering, operationsand maintenance costsl Maximise plant and productionefficiencyl Improve production qualityl Protect people, plant assetsand the environmentl Maximise return on investment2

We understandyour challengesThe challenges faced by today’s process industries have been multipliedby the volatile state of the global economy. In this type of environmentthe demands on the process control system are increased, going beyondsimple regulatory functions. It becomes a tool to manage the plant,decrease energy consumption, reduce costs, cut emissions and providequick and precise information from the field to support production andbusiness decisions.What does it mean for you?For plant managers> Ensure the safety of people, plant andthe environment> Optimise asset utilisation> Improve the plant profitability> Reduce environmental impact> Optimise energy efficiency.For operations managers> Improve plant availability> Optimise costs while maintaining the rightquality level> Maximise production efficiencies.For the engineering teams> Implement standardisation and ensurestandards are met> Reduce engineering times to accelerate projectschedules> Manage local and remote engineering teams> Administer the entire system from a singlelocation.For plant operators> Ensure process stability> Anticipate process disturbances> Prioritise actions> Act on important alarms or events.For maintenance teams> Implement effective maintenance programs> Identify root cause of problems as quicklyas possible> Standardise maintenance procedures.It is important to ourbusiness that we enterstrategic partnerships withorganisations that hold thesame values that we do.Schneider Electric has aclear focus on solutionsfor operational excellenceand energy efficiencyand we challengeSchneider Electric tounderstand our businessand offer solutionsthat helps drive itsperformance.3

Our experienceis your advantageSolutions are not solely based on technology but also the expertise behindthe technology. At Schneider Electric we have been delivering solutionsfor manufacturing and process industries for over 40 years. We understandwhat is needed to help you meet your goals in automation and energymanagement.An history based oninnovationMore than 40 years ago, we invented the firstPLC and paved the way for companies to driveefficiency by replacing physical logic relays byprogrammable logic controllers.In 1979 we introduced Modbus to the market,a de facto communications standard, truly openand the most widely used industrial protocol inthe world.In 1996 we introduced our first programmableautomation controller (PAC) with embedded webserver capabilities and onboard data logging.We have a history based on innovation andopenness, and today we continue in the samespirit with the introduction of PlantStruxure TM .A leader in processautomationWe have come a long way since we installedour first PLC and today we are amongst a selectfew as a leader in process automation, deliveringsolutions for all types of applications. Weunderstand that each application is unique andthat is why we offer a system that can be tailoredto meet the needs of all types of processesincluding discrete, batch, continuous, safety ora combination.Delivering solutions acrossthe enterpriseWe have an unmatched automation offer fromthe sensor that measures your process and theautomation system that controls your productionto the historian and manufacturing executionsystem that helps you to improve your productionefficiency and achieve operational excellence. Allthis coupled with the ability to provide integratedenterprise wide energy efficiency solutions andbacked by a team of dedicated professionalsfocussed on delivering the solution you need.A leader in energy efficiencyNot only are we a leader in process automation,but we are number one in energy efficiency. Everyday we help companies to identify and implementways to reduce their energy consumption anddecrease their environmental footprint.EcoStruxure TMEcoStruxure TM is the solution ecosystem based upon active energymanagement architectures, from Power Plant to plug, offering guaranteedcompatibility across data, power, security, cooling and automation andleveraging open standards across both Schneider Electric and third partyoffers. This approach will enable customers to create intelligent energymanagement systems that are simplified, save on Capex and Opex, andmost importantly, reduce waste, delivering up to 30% savings in energyefficiency. PlantStruxure TM is a building block of EcoStruxure TM .4

PlantStruxure TM is a collaborative system that allows industrial and infrastructurecompanies meet their automation needs and at the same time deliver ongrowing energy management requirements. In a single environment, measuredenergy and process data can be analyzed and used to yield a holisticallyoptimised plant.Scalablefor changing timesFrom tens of I/O to hundreds ofthousands, the scalability of our systemmeans that you can start out small andgrow as your requirements change.Integratedto reduce riskThe system is integrated inside, from devices toMES all of the system components are designedto work together with each other and with ourchosen technology partners.FlexibleCollaborativebecause your process is uniqueOur system supports the architectures thatyou need for your application. Single site,multiple sites, distributed control, localcontrol, discrete, process, safety, batch allwithin the one system.to increase efficiencyOur system is open to exchange informationwith other plant and business software, andfosters an environment of collaboration bydelivering the process information you need inthe way that you like to see it.5

A system for processand energy managementIn order to meet your challengesyou require a control system thatis not only easy to engineer andsimple to maintain, but that deliversa clear picture about what ishappening in your process.You need a control system thatcan easily integrate with third partydevices and that provides addedvalue in the form of Historian andManufacturing Execution Systemfunctionality. In short, you need asystem that drives increased returnon assets and meets the needs ofyour application.The unique features such as Global Data access,high availability and distributed architectures alongwith hot-standby redundancy and more, meansthat our system offers everything you need tomeet your process automation requirements.Energy Management> iPMCC to optimise energy consumption> Smart power and energy meters> Variable speed drives for better energyefficiency> Energy management software to measureand analyseManufacturing Execution System> Real-time access to plant and business information allowing key personnelto identify and act on opportunities to maximize plant and process efficiencyand to correct problems before they impact on supply chain, regulatorycompliance and production.6

Transparent Ready Networking> Transparent communication between all systemcomponents> Standard Ethernet technology and industrialprotocols> Dedicated device networksupport includingModbus TCP, EtherNet/IP, Profibus, CANopen,AS-Interface> Support for dedicated instrumentation busessuch as Profibus PA, Foundation Fieldbus &HART.Operation> The link between the operator and the process> Easy system navigation> Powerful alarm management> Advanced trending and process visualisation> A range of client options including web clients,PDAs, smart phones.Control> Scaleable family of programmable automationcontrollers to meet all control requirements> Integrated SIL2 safety> Hot-swappable processors, I/O andcommunications modules and power supplies> Advanced process control functionality> Configuration based on IEC61131-3 standard.EngineeringHistorian> Collects all process, quality, energy and other data from across your siteand generates detailed reports to help the decision-making process> Based on industry standard technologies> Data security to prevent unauthorised viewing or tampering.> Engineer and modify your entire system from asingle location> Flexible engineering tools in order to supportyour efforts to be more efficient> Reusable and extensible object libraries forstandardisation> Off-line simulation to reduce testing andcommissioning.7

8Transparent informationaccess from your plantfloor to your enterprise

Transparent Ready NetworkingTransparent Ready networking allows the establishment of transparentcommunication between field, process, plant and enterprise. Networktechnologies and web services guarantee the efficient sharing anddistribution of information between sensors, instrumentation, devices,controllers, operator workstations and other third party systems.Standards basedcommunicationBased on standard Ethernet technology andindustrial protocols Transparent Ready protectsyour system investment as technology evolves.It offers significant savings in the design,installation and maintenance of your systemand reduces training requirements.Real-time data accessModbus TCP and EtherNet/IP, the most provenand reliable industrial protocols available today,facilitate the real-time data exchange betweensystem components such as controllers anddevices, guaranteeing robust communication foryour system.Because the communication backbone isEthernet, it seamlessly communicates to all thirdparty devices via a range of standard industrialprotocols. It is also easy to connect and manageyour field instrumentation via Profibus, FoundationFieldbus or HART, to reduce installation costs andsupport predictive maintenance programs.Time-synchronizationsystem-wideThe system features automatic timesynchronization between all components, withthe option to integrate hot-standby time servers.This ensures that all alarms, events and otherinformation are stored and displayed in the orderthat they occurred to provide a clear picture of thestatus of your operations.Advanced featuresTransparent Ready offers all of the standardfeatures above and more, including:> Faulty device replacement technology toautomatically configure replacement devices in thesystem and cut maintenance time> Event notification via email directly from thedevice> Inbuilt web servers with onboard data loggingto reduce maintenance and increase systemflexibility.The advanced features of Transparent Ready offeryou the flexibility to choose the right architectureand level of features to meet your processrequirements.Ethernet – fastest growingtechnology in industrialnetworks +27% CAGR ofEthernet devices to 2012 **Source ARC Report 20089

EngineeringAccelerating yourengineering workflowWe offer flexible system engineering tools in order to support your effortsto be more efficient. These tools are focussed on helping you to accelerateyour control system configuration, significantly reducing your engineeringtime and minimising your project risk.Reduced project schedulesA combination of single data entry, feature-richobject libraries, collaboration with third partyprocess design software and the ability tostandardize and reuse your engineering bestpractiseshelps to dramatically decrease the timeit takes to design, engineer, install and commissionyour system.Standardise,reuse and extendOur system delivers an object-based approachto your configuration and includes feature-richapplication libraries specifically focused on theprocess industry. Engineers can use the librariesas they are or take advantage of their extensiblenature in order to augment the library to meetspecific standards. Once created, user definedobjects are available for reuse in the sameapplication or on subsequent applications, cuttingdevelopment time and reducing project risk.10

Integration with processdesign softwareOur system provides you with the option tostructure and organise your application accordingto the process functional diagram of your plantand offers an open interface to provide easyaccess for a large number of process designsystems. This open interface can be used toexchange process and system design data withthird party applications and remote engineeringteams, removing the need to configure the systemfrom scratch.Off-line simulationOur expertise> Single data entry to avoid errorsduring configuration> Reusable and extensible objectThe simulation function built into the systemenables engineers to replicate the functionalityof the application in a PC environment. Thishelps to identify any errors in the applicationprogramming and decreases testing andcommissioning time.libraries30%> Open interface to process andelectrical design tools> Change tracking anddocumentationreduction in projectschedules11

12Access to real-timeinformation for efficientprocess operation

OperationThe system operation environment-delivers operators with all the datathey need along with the customisation features they require to operatethe process in the manner that suits them.The whole pictureUnify any number of control systems, or processunits into a single, “clustered” system. Using thisfunctionality each local site can view their ownprocess and use global control clients to viewacross the entire plant. Complete with unifiedalarm lists and the ability to compare trendeddata across multiple areas, clustering providesa balance between stand-alone reliability andcentralised maintenance.Built for control roomsand the plant floorThe ability to extend your plant operations fromthe control room to the plant floor is importantand that is why we offer dedicated plant floorHMIs built to withstand the rigours of these typesof environments. The ruggardised features of thisrange make them perfect for use in plant floorcabinets and other dedicated applications.Understanding the dataKey to driving efficiency during plant operationis the ability to provide operators with clearinformation about the process. That is why thesystem provides, not only a state-of-the-artgraphical interface, but also advanced alarm andtrend acquisition features. The acquisition systemsare designed to support both time-stamped (forexample from RTUs) and real time data in a singleoperations environment.Getting to the causeof the problemTo diagnose the cause of a disturbance and torectify the situation it is important to understandthe circumstances surrounding the incident. Thealarm list feature provides operations staff with ahighly flexible method for filtering and sorting bothactive and historical alarms, supporting both alarmgrouping and hierarchical suppression. Coupledwith this is the process analyst which integratesalarm and trend information with operatorcomments in a single view in order to quicklyidentify when and where an incident occurred,helping to facilitate a swift resolution and preventsuch occurrences in future.Accessing informationfrom outside the plantAccess plant and process data from outsidethe plant via dedicated web clients and smartmobile devices such as PDAs, or mobile phones.This type of functionality is designed for peoplewho need access to real-time plant and processinformation from remote locations.Ourexpertise> State of the artgraphical interface> Process Analyst> Advancedalarming andtrending> Dedicated plantfloor HMI> Web clientaccess13

Programmable Automation ControllersA family of controllersto meet your uniqueprocessing needsA family of programmable automation controllers to meetyour unique processing requirements.14

Built for processapplicationsOur programmable automation controllers arebuilt for the needs of the process industry, thehardware is modular and scalable and supportsa full range of input/output modules alongwith dedicated communications and fieldbusmodules for connection to smart devices andinstrumentation.The controllers support high density options toreduce cabinet space and system cost and offerconformal coating for harsh environments andhigh isolation levels for immunity to noise in difficultelectrical environments.Our system also offers the ability to distribute thesystem IO into the field and install it close to theprocess, helping to cut wiring and installationcosts.Regulatory and advancedprocess controlEach processor is multitasking meaning that youget the fastest and most efficient processingof your control algorithm, communication andIO processing and all controllers support all ofthe five IEC 61131-3 programming languageswithout restriction to provide a broad range ofconfiguration flexibility.> Function Block Diagram (FBD)> Structured Text (ST)> Sequential Function Chart (SFC)> Ladder Diagram (LD)> Instruction List (IL)The prebuilt object libraries provide all of thefunctionality needed for continuous or regulatorycontrol and additional libraries are available forthose applications that need advanced processcontrol functionality, including> Fuzzy logic> Multivariable Predictive Control> Statistical Process Control.Easy maintenanceOur expertise> Regulatory and advanced process controlfunctionality> Modular, scalable and distributed> Hot-swap and redundant capabilities> Complete range of IO and fieldbuscommunication modules> Suited for harsh environments and areas ofhigh noiseEach controller features hot-swap capabilitiesfor power supplies, input/output modules andprocessors as well as automatic configurationon insertion meaning that you can performmaintenance without the need to shut down orstop your process.15

16Protecting your people,plant and processes

Safety Instrumented SystemIn order to protect your people and the environment, to ensure that your processis safer and more efficient, and to meet safety best practice as defined in theIEC 61511 standard, we offer a solution for your safety system requirements basedon a worldwide recognized offer and proven technology.Our Collaborative Control system delivers the flexibility to combine both safetyand process applications in the one system.Safety in harmony withthe processSo that you can design your safety applicationsmore simply, the SIS (Safety Instrumented System)offer is a direct extension of the standard processautomation offer. The hardware architecture,communication networks and configurationenvironment are identical to the ones you alreadyknow, helping to minimize the training required.This commonality between the SIS and processcontrol system allows for easy maintenanceand seamless integration into the operatingenvironment of the control system. The safetysystem features hot-swap functionality: hotswapIO communication modules CPUs andpower supplies reducing both the operating andmaintenance costs of the system.With the hot-standby 1oo2 hot repairconfiguration, when the SIS detects a fault, theprocess control continues to operate. And more,with an option of full redundancy the system offersthe ability to repair any fault without interruptingthe safety system. This avoids spurious trips andguarantees that the system is brought to a safestate only when an unsafe situation is detected.Protect Your InvestmentWith this common integrated safety offer, youcapitalize on your development know-how andyou integrate the safety functions within yourexisting installations more simply.By preserving the availability of your plant andoptimizing your asset costs without compromisingsafety, the Safety Instrumented System improvesthe return on your production assets.Our expertise> TUV certified for use in SIL2 or SIL3applications> IEC 61508/61511 functional safety> Hot-standby 1oo2 hot repair functionality> Based on standard networks and opensoftware systems> Integration of safety and process control ina single platformMTTF up to 2,000 yearswhen implementing a hot-standbysolution17

High AvailabilityFor 24 x 7 operationof your processOur systemoffers theflexibility tochoose the levelof availabilityto meet yourparticularapplicationand provideshigh availabilityoptions atall levels ofthe systemarchitectureincludingoperatorstations,data servers,controllersand networks.So for thoseapplicationsthat need tobe operational24 hours perday, 7 days perweek and wherea stoppage tothe processcan not betolerated – theanswer is here.18

Don’t change your habitsConfigure your redundant system in the same waythat you would for a non-redundant system. Thereis no need for specific application programming atthe controller level and network and data serverredundancy is managed in a few seconds with thehelp of a simple setup wizard.Online changesTo ensure uninterrupted processing we offeronline change functions for the controllers inorder to update your application simply andsecurely without interrupting your process. Whenemploying a redundant data server configurationyou have the option to make changes to theconfiguration and role-back these changes if theydo not operate as expected, all without disturbingproduction.In order to ensure easy maintenance the systemcontrollers feature hot swap capability forprocessors, cables, input/output modules andpower supplies.Automatic and bumplessThe hot-standby nature of the controllers, dataservers and networks means that a failure of theprimary component results in the automatic andbumpless switch to the standby. This switchis transparent to the operator and the processcontinues to operate as normal. The redundancyfeatures are integrated into the alarm system,meaning that the operator will be automaticallynotified in the case of any failure.99.99996%availabilityOur expertise> Automated IP address managementbetween primary and secondary controllers> Transparent operator client switching inthe case where the primary data server fails- without loss of data> Integrated system alarm management> Scalable, redundant HIPER ring networktechnology19

20Smartinstrumentationand web-enableddevices to reduceyour maintenance costs

Device ManagementThe combination of smart instrumentation, web-enabled devicesand Ethernet as the system communication backbone providesusers with access to device data and configuration informationthat was previously only accessible locally, or within specificprocess areas. This global access to data cuts maintenancecosts, eases configuration and reduces commissioning time.Fieldbus and devicenetworksMany of the efficiency improvements in yourprocess come from the ability to predict problemsand prevent failures. Process fieldbuses and opendevice networks make it easy for you to realisesignificant savings in the maintenance of yourplant assets and process equipment by deliveringthe advanced information that you need toperform maintenance tasks before a break-downoccurs.Reduce installation costsAlong with this are the cost-savings offered duringthe design and installation of your system. Thanksto the features of these smart networks you useless wiring, meaning less cabinet space and fewersystem design drawings.Open fieldbus policyOur system brings you all of these benefits thanksto our open fieldbus policy.Smart field instrumentation:> HART> Profibus PA> Foundation FieldbusMajor device networks to integrate sensors,drives and motor control:> EtherNet/IP> Profibus DP> Modbus TCP> CANopen> AS-InterfaceWeb-enabled devicesOur range of smart web-enabled motor controldevices and drives allow you to configure andsave parameters from anywhere in the system,and what’s more they support Faulty DeviceReplacement (FDR) technology to automaticallyreload the configuration into a new device in thecase of a failure. Helping to cut maintenance timeand reduce system related process downtime.Support for FDT/DTMFDT/DTM technology is device manufacturerindependent and fieldbus communication protocolindependent and provides a single environmentfor field device configuration, field devicecommissioning, and the ongoing managementof field devices. Our system supports FDT/DTMin order to help you minimise maintenance andpreserve your investment in existing field devices.Improve your assetutilisationFurther leverage the benefits of smartinstrumentation and devices by transparentlyintegrating the data into dashboards and smartanalytics using our Manufacturing ExecutionSystem, thereby providing a complete pictureof your maintenance information, downtimeinformation and performance metrics in a singlelocation.21

Energy ManagementReduce your operatingcosts with energymanagement initiativesIn the past power and controlwere two separate worlds.However, today, companiesunderstand that in order tooptimise their processesand reduce operating coststhey need to implementstrategies that include both.Combine process informationand energy information inthe one system providing asingle interface for all yourprocess and energy needs.Process control and energy efficiencygo hand in handOur smart power and energy meters allow you to collect data from all ofyour energy sources, such as water, air, gas, electricity and steam, andmake this available in the system. Combining this information with otherprocess related data provides a clear picture on your per unit energyconsumption and helps to pinpoint areas for improvement within yourprocess.> Reduce peak demand surcharges> Implement dynamic load-shedding strategies within the control system> Reduce power factor penalties> Leverage existing infrastructure capacity and avoid unnecessary capitaloutlay> Support proactive maintenance to prolong asset life.Up to 60%of energy consumption in a plant is from motors22

With proper process control andmonitoring capabilities, you can ensurea high quality finished product whileoptimising your energy consumption.Electric motors, a critical target forenergy efficiencyOur variable speed drives are an excellent way to optimise the energyefficiency of the electric motors in your plant, like those used for fans, pumpsand conveyors throughout the plant.Your benefits are immediate:> Significant energy savings from reduced energy consumption> Optimised process control thanks to transparent integration with the system> Longer motor life and reduced maintenance costs.iPMCC a valuable ally inenergy savingsOur iPMCC (Intelligent Power and Motor Control Center) solutions seamlesslyintegrate through use of the the best network architectures, motor protectiondevices and variable speed drives.iPMCC brings intelligence to motor control:> System availability based on networks with fewer potential failure points> Fewer shutdowns thanks to remote access and advanced problemidentification> More information available to aid effective decision-making> Energy savings by use of high-performance variable speed drives> Flexibility of solutions based on multiple networks.23

24Daily, weekly andmonthly productionfigures at your fingertips

HistorianThe Historian collects your process, quality, energy and other datafrom across your site and generates detailed reports to help thedecision-making process.Information anywhere,anytimeSeamlessly connect to your production andbusiness systems to ensure that the right peoplehave access to any information that they need.This is made possible by our ability to bringtogether high speed and real-time productiondata with the universal accessibility of a businessdatabase within our historian offer.A range of clients fora range of users> Maintenance engineers need a fast way toanalyse trend and event data. The Historian WebClient delivers a flexible way for them to comparereal-time and historical data in the one interface.> For many process engineers, Microsoft Excelis the tool of choice for data analysis. It providesthem with all the calculation tools that they needto model and analyse production. The HistorianExcel Client adds value to these models byintegrating data directly from the control system.> Managers prefer their data presented graphicallywith the ability to drill-in for more detail. Byutilising industry standard reporting tools, suchas Microsoft Reporting Services, the Historianprovides a highly customisable reporting systemthat can be easily integrated with the overallreporting needs of the business.> For other applications such as business systemsintegration, or data analysis the historian providesdata though open standard interfaces (OLE-DB,XML, Web services) enabling your plant to reactand interact with most business systems.Data collection &management> Your data collection is secured via support forredundant and the ability of the Historian to backfilldata in the event of network or Historian failure.> The data collected includes any tags, alarmsand events from within the system as well as eventor tag comments in order to provide a rich sourceof information for data analysis.> Utilising data from your control system, or bydirectly connecting to external data sources, suchas Laboratory Information Management Systems(LIMS), the Historian provides a centralisedlocation for all of your process data storage needs.Know that your informationis safeThe combination of industry standard technologiesand single sign-on for valid system users ensuresthat any sensitive data stored within the Historianis safe from unauthorised viewing or tampering.Mr Tarun KhulbeVP & Chief Cold RollingDivision: Jindal Stainless– India“This was one of mydream projects wherewe wanted to establishan information bridgebetween shop floor andtop floor in terms of realtimeprocess information.We wanted to equip ourmanagers in such a waythat they have visibility andcontrol of the processesall the time, across theplant.”25

26Total traceability fromraw materials to finishedproduct

Batch ManagementIn many industries having full control over batch processes is key to productivity andquality.Our batch management offer is a fully integrated batch management and trackingsoftware compliant with the latest version of both the S95 and the S88 standards. Itprovides you the agility and control to respond to increasing production demands inreal-time. It helps you to reducing lifecycle costs and production downtime as well asto keep track of batch history and data for regulatory compliance. In other words, itenables you to achieve and sustain a competitive advantage in the marketplace.42%Increase in the numberof product recalls in theUnited States duringthe last 3 yearsFlexible manufacturingBatch management enables manufacturers tomanufacture a variety of products, to react quicklyto changing customer schedules or unexpectedplant-floor events and to easily introduce newproducts.Each product is based on a flexible recipeconsisting of a procedure and a formula and canbe easily created or modified by the processengineers or the production operators without anyspecific automation background.During operation, the production team scheduleproduction orders indicating the order size, themaster recipe to use and the specific parameter,the system will automatically create the numberof batches required according to the equipmentcapabilities. Scheduled orders are displayed ona Gantt type display giving a clear overview of theproduction planning and allowing simple changesin priorities.During a production batch, the operator hasaccess to the current status of the phases beingexecuted along with an overview of the wholeprocedure and the main control parameters of thebatch.Faster time to marketOur batch management offer is based on aS88/S95 object oriented plant model to reducethe development and validation costs through asimple procedure: develop and test once, reuseeverywhere.Phase logic objects are available to providestandard interface for both operator and batchmanagement software managing all the types ofinteraction in respect with security and traceability.As a result, our system empowers engineers todesign complex and flexible production strategies.Keep track of batchinformationAutomatically record all information required forthe generation of comprehensive batch reports.The data is stored locally in a secure databasefor reporting purposes and connects with theHistorian and Manufacturing Execution Systemto provide you with a total picture of your plantoperations.Ease regulatory complianceFor processes subject to licensing by regulatorybodies such as the Food and Drug Administration(FDA), our system provides the tools you need toachieve compliance. Security, audit trail, changemanagement, electronic signature, automatedreporting, archival and retrieval are integral toall operations and system applications. Ourbatch management offer automates, monitors,controls, and documents cGMP (current GoodManufacturing Practices) compliance of yourmanufacturing processes.27

Vince AuroraPlant Manager,Angaston - AdelaideBrighton Cement“Our challenge wasto replace multiple,disparate downtimereporting systems witha single system thatwas automated, easyto use, and enabled thereal-time collection ofstoppage data acrossour operations. Ampla(Schneider MES solution)Downtime was chosenas a best-of-breedsolution because it metthese criteria, and sinceits commissioning, ABCAngaston has reducedplant stoppages by morethan 50%.”Make prioritiseddecisions aboutyour processand operations28

Manufacturing Execution SystemOur Manufacturing Execution System delivers realtimeaccess to operational and production informationenabling organisations to improve their competitivenessin global markets, increase shareholder returns,increase operational efficiencies and reduce energyconsumption.It is a powerful and dynamic suit of manufacturingoperational software used to overhaul businessprocesses and particularly look at manufacturing costs,production efficiencies and quality.In addition, it empowers manufacturers to:> Reduce operating costs> Optimise production> Increase first-pass quality> Decrease waste and reject> Gain visibility of real-time data directly from plant floor> Make decisions based on reliable manufacturing data.Connecting to plant and business systemsOur Manufacturing Execution System connects to multiple plant and businesssystems, collects the relevant data and presents it as easy-to-understand,real-time intelligence for productivity analysis, data mining, querying andreporting.It is used to identify bottlenecks, analyse production downtime causes,calculate key performance indicators, deliver accurate views of productioninputs and outputs, understand your work-in-process, track the real costs ofproduction and many more operational performance issues.Sustainable architectureThe MES system has been built to meet the needs of complex and evolvingIT requirements by integrating leading edge technologies, sustainablearchitecture and strong web services capabilities.It supports easy integration to all major ERP vendors, is highly configurableand flexible and easy to integrate.Up to 25%Improve performance up to 25% by increasingvisibility and management of daily operations29

Schneider Electric ServicesWe have you coveredthrough every stage ofyour system lifecycleWe support you throughout the life of your plant, from the design, throughoperation and modernisation. We offer expert services available in all countries.Our network of project and service centres combined with our unparalleledpartner network is at your disposal to deliver the solution you need.50More than 50 TrainingCentres WorldwideProject Management andProject EngineeringYou can count on the experience andinvolvement of our teams.Schneider Electric has global and local projectteams to manage your automation, energymanagement and electrical distribution projects.With worldwide references in across all industriesand with strategic presence in major countries,Schneider Electric is the right partner for yourproject and engineering challenges. Our tools,standards and proven processes allow us toapply these best practices in your project with theconfidence, safety and quality you want.500More than 500dedicated projectexperts and engineersConsultancyOur experts and consultants help you toanalyse your existing situation and worktogether with you to define and deploy specificsolutions to meet your particular requirements.> For operationWe support you to get more from your plant.For example, as process automation specialists,we provide consultation services and audits tounderstand, evaluate and propose solutions andstrategies to improve the bottom line of yourbusiness, optimise your process efficiency andachieve energy savings.> For pre-project phaseOur consultants can help you to integrate yourprocess with your business and offer solutions onthe best process control architectures, intelligentmotor control centres philosophy, energymanagement networks and electrical distributionsolutions according to your requirements andbudget objectives.Alliance PartnersFor specialty process know how, SchneiderElectric has a strong worldwide network ofsolution partners that comprise the majorEPCs, OEMs and System Integrators in theindustry.Within this collaboration environment, youhave the access to a strong combination of thebest process providers and Schneider Electric,delivering a powerful and complete solution.30 8

TrainingWe can help you identify your trainingrequirements by systematic analysis of levelsand functions of your teams, propose trainingmodules covering your installed automationequipment, follow up acquisitions by ongoingtraining, offer training modules designed tosuit your timing and locations.We have over 50 training centres worldwidecomplete with high technology learning tools,professional trainers expert in both industryneeds and education and can offer standardor customised courses on your site or at ourpremises.Replacement Parts andRepairsDoes your competitiveness depend on yourreactivity to breakdowns and malfunctions?We can help you limit downtime periods.> From our stock we can supply you with testedand certified replacement parts compatible withyour installed equipment> By contract, we offer to store in your warehousereplacement parts for the system that remain asour remote stock until required> Finally, you also have access to a strongdistribution channel network, present worldwide,with which to have fast access to our products.Maintenance & SupportContractsWe offer a range of flexible and customisedservice contracts to meet your needsincluding.> Telephone support for priority access to ourexpert support centre> Web access to benefit from the latest softwareversions> Stock of our approved replacement parts onyour site or in our warehouse> Assurance of on-site assistance within aguaranteed timeWe help you anticipate technical risks and performessential modernizations by taking account ofequipment obsolescence, in order to avoid costlyproduction shutdowns.900More than 900Alliance SystemIntegrators25More than 25Automation SolutionCentres WorldwideOur offers help you to> Anticipate risks> Improve your performance> Keep control of your investments31

Make the most of your energySchneider Electric Industries SAS35, rue Joseph MonierF-92500 Rueil-MalmaisonFRANCETél. : +33 (0) 1 41 29 70 00www.schneider-electric.comDue to possible changes in standards and equipment, the features described in this documentin the form of text and images are subject to confirmation by Schneider Electric.Publication: Schneider ElectricPhotos: Chris Ryan / GettyImages - Jaques Dussouillez - Eliandric / Istockphoto - SchneiderElectric - Christian Lagerek / Shutterstock - Rudi van der Walt / Fotolia - Olivier Digoit / Andia- José Antonio Rojo / Rojofoto - Keng Guan Toh / Shutterstock - Creatas / JupiterimagesDesign: pemacoDIACED1109301ENART.83740310/2009